Porch apparatus for modular structures with adjustable stair and handrail assembly

ABSTRACT

A modular and dismantleable porch apparatus including a deck frame for supporting decking material, a handrail assembly attached about the circumference of the deck frame, an modular step assembly attached to the deck frame, and a modular handrail assembly attached to the step assembly. The deck frame is constructed of a plurality of support members having swedged ends that interlock to form a rectangular body. The step assembly is constructed of step frame members that may be added as needed to add additional steps. The handrail assembly also provides a modular design using handrail segments with swedged ends in which additional rail segments may be added to accommodate the length of the completed step assembly.

PRIORITY CLAIM

[0001] The present application claims benefit of U.S. ProvisionalApplication No. 60/361,831 filed on Mar. 5, 2002.

BACKGROUND OF THE INVENTION

[0002] 1. Field of the Invention

[0003] The present invention relates generally to deck assemblies andmore particularly to a portable deck apparatus designed and configuredto be easily and successfully installed and/or dismantled by providingan apparatus with a frame system that is adapted to be altered in sizeso as to accommodate any modular structure.

[0004] 2. Description of the Prior Art

[0005] Modular structures, such as mobile homes or the like, generallyhave one or more doors for providing access into the particulardwelling. Generally, these doorways are situated substantially aboveground and entrance to the door requires the use of steps. The stepsthat are often provided with the modular structure lack a porch area,and in addition these steps tend to be small in size and structurallyunstable. Thus, this conventional design inherently provides an entrancesystem that can be inadequate and precarious especially for the elderly,toddlers and those with limited dexterity.

[0006] In the past, adding a porch to a modular structure required acustom-built installation, which could be costly. Should the modularstructure be relocated, the porch must be dismantled. Disassembling thecustom-built porch can be a tedious and laborious process, especially iftrying to salvage the components. Storage and transportation can also bea concern, since the salvaged components are varied in size and shape,thus providing items that are bulky and awkward to handle. In addition,due to the various slopes and elevations of the ground, the priormaterial used for the custom-built deck may not be useable for the newlocation of the modular structure since the ground structure will not beidentical to the previous site.

[0007] As such, modular ready to assemble decks and porches for use withmodular structures have been developed. For example in U.S. Pat. No.5,784,837 there is disclosed a collapsible transportable deck having aframework that includes ground-engaging wheels mounted for rotation atthe bottom of the framework. A coupling at the front of the deck is usedto facilitate connecting the deck to a towing vehicle. Thus, rendering adeck that is adapted to be towed to a desired location for use.

[0008] Another modular porch for use with a mobile home that addresses asolution to the problems associated with varying slopes and elevationsof the ground is disclosed in U.S. Pat. No. 4,852,309 and in U.S. Pat.No. 3,808,757. In these patents there is disclosed a modular porchhaving vertically adjustable support legs, wherein, each leg isindependently axially adjustable.

[0009] Though the modular units described above may be successful, theyoffer assemblies that tend to be numerous in components and complex indesign. Due to the excessive number of elements, installation anddismantling can be time-consuming and frustrating.

[0010] Accordingly, it is seen that there is a need to provide a deckapparatus for a modular structure that is successful in operation,aesthetically pleasing when installed, yet simple to assemble anddismantle. The disassembled structure should be compact for renderingeasy transportation capability. This deck apparatus should include ameans for accommodating different types and styles of modular structuresand varying elevations and slopes of the terrain.

[0011] As will be seen, the present invention achieves its intendedpurposes, objectives and advantages by accomplishing the needs asidentified above, through a new, useful and unobvious combination ofcomponent elements, which is simple to assembled, with the utilizationof a minimum number of functioning parts, at a reasonable cost tomanufacture and by employing only readily available material.

SUMMARY OF THE INVENTION

[0012] The present invention is a modular and easy to assemble porchapparatus for use with a modular structure. In a disassembled state, theporch apparatus is compact for rendering a unit that can be transportedeasily and one that does not require an excess amount of space forstorage. This porch apparatus is simple in design for reducing the timeand effort for assembling and disassembling the deck, while notcompromising on quality and structurally stability. In addition, toincrease its versatility, this porch apparatus is designed andconfigured to vertically adjust in order to fit any modular home andaccommodate any elevation and slope of terrain, innately providing adeck that is leveled, aesthetically pleasing and structurally sound.

[0013] The present invention provides a modular porch apparatus for usewith modular structures. The porch apparatus comprises a deck assemblyhaving an adaptable stair assembly coupled thereto and an adaptablehandrail assembly coupled to the stair assembly. The deck assemblycomprises a frame member that is adapted to support and receive flooringfor the porch. Removably secured to the frame are independentlyadjustable legs. Secured to the flooring, opposite from the legs, is thevertical railing. The frame member and railings include interlockablemembers that facilitate the assembly and disassembly process. The stairassembly, having vertically adjustable legs, is secured to the framemember.

[0014] Other features can be added for enhancing the final porchassembly. These features include, but are not limited to; providing aroughen surface on the steps and/or deck, providing a canopy over thedeck area. The adjustable step assembly includes the ability to addadditional steps to the step structure, and the adjustable handrailsystem on the steps provides the ability to adapt a correct lengthhandrail apparatus to step assembly depending on the desired height ofthe steps.

[0015] Accordingly, it is an object of the present invention to providea modular porch apparatus that will overcome the deficiencies,shortcomings, and drawbacks of prior modular porches and methodsthereof.

[0016] Another object of the present invention is to provide a porchapparatus that is easy to assembly and disassemble and one that canaccommodate any modular structure and terrain elevation, ultimatelyproviding a well structured and leveled porch.

[0017] Yet a further object of the present invention, to be specificallyenumerated herein, is to provide a porch apparatus in accordance withproceeding objects and which will conform to conventional forms ofmanufacture, be of simple construction, fabricated from durable andanti-corrosive material and easy to use so as to provide a dismantleableporch apparatus that would be economically feasible, long lasting andrelatively trouble free during utilization.

[0018] Although there have been many inventions related to dismantleableporch apparatus, none of the inventions have become sufficientlycompact, low cost, or reliable enough to be utilized. The presentinvention meets the requirements of the simplified design, compact size,low initial cost, ease of installation and maintainability, and minimalamount of training to successfully assembly and dismantle the invention.

[0019] The foregoing has outlined some of the more pertinent objects ofthe invention. These objects should be construed to be merelyillustrative of some of the more prominent features and application ofthe intended invention. Many other beneficial results can be obtained byapplying the disclosed invention in a different manner or modifying theinvention within the scope of the disclosure. Accordingly, a fullerunderstanding of the invention may be had by referring to the detaileddescription of the preferred embodiments in addition to the scope of theinvention defined by the claims taken in conjunction with theaccompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

[0020]FIG. 1 is a perspective view of the assembled dismantleable porchapparatus of the present invention.

[0021]FIG. 2 is a perspective view partially exploded to show theassembly of the stair unit used in combination with the assembled porchshown in FIG. 1.

[0022]FIG. 3 is a top view of the components used in the frame memberfor the deck assembly of the dismantleable porch apparatus of thepresent invention.

[0023]FIG. 4 is a sectional perspective view from the lower frontright-hand corner of the porch apparatus exploded to illustrate theassembly thereof.

[0024]FIG. 5a is a sectional perspective view of the assembled porchapparatus showing the assembly thereof in enhanced detail.

[0025]FIG. 5b is a sectional perspective view from the upper frontright-hand corner of the porch apparatus exploded to illustrate theassembly thereof.

[0026]FIG. 6a is a plan view showing the leftmost vertical railingsupport member.

[0027]FIG. 6b is a plan view showing the right front vertical railingsupport members.

[0028]FIG. 6c is a plan view showing the right rear vertical railingsupport members.

[0029]FIG. 7a is a plan view showing a first upper horizontal railingmember.

[0030]FIG. 7b is a plan view showing a second upper horizontal railingmember.

[0031]FIG. 8a is a plan view showing a first lower horizontal railingmember.

[0032]FIG. 8b is a plan view showing a second lower horizontal railingmember.

[0033]FIG. 9 is a sectional perspective exploded view showing theassembly of the lower horizontal railing member to a vertical railingsupport member.

[0034]FIG. 10 is an exploded perspective assembly view showing theassembly of the modular stair handrail assembly and step assembly.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

[0035] With reference to the drawings, the present invention, adismantleable and modular porch apparatus, denoted by reference numeral10 will be described. Shown is a porch apparatus 10 designed andconfigure to fit and accommodate any size modular structure, such as amobile home. The present invention is an apparatus that is easy toinstall and one that will successfully provide a porch apparatus that islevel and aesthetically pleasing. As seen in FIG. 1, the dismantleableporch apparatus comprises a deck assembly 12 having a stair assembly 54coupled thereto, and optionally, a handrail assembly 62. Most of theparts in each assembly include male ends, such as 32 and 76, that areswedged to have a reduced circumference or female ends for receiving theswedged ends and interlocking the parts together.

[0036] The deck assembly includes a main frame or deck frame 14 as shownin FIG. 3. The main frame 14 includes a plurality of support members 16a-16 e that interlock with one another. Once appropriately coupled, thesupport members 16 a-16 e form the substantially rectangular main frame14. To enable such a configuration, the support members 16 a-16 einclude a plurality of altering configurations. One configurationprovided is the use of a C-shape member. In the main frame, there willbe a pair of C-shape members 16 a having elongated tubular bodies. Theouter perpendicular flanges of the C-shape member are male receivingends. One end of this C-shape member includes a female receiving end.This female receiving end is perpendicularly located with respect to themale perpendicular flanges on each end.

[0037] Coupled to the C-shape members 16 a, on the interior of the frameis a support member 16 b having two male ends oppositely located. Thefirst male end as seen in FIG. 3 is perpendicularly located with respectto the second male end. This second male end is adapted to be located inthe female end of the first support member 16 a.

[0038] Secured to each pair of outer male ends formed from the firstsupport members 16 a and the second support members 16 b is an elongatedsupport member 16 c having a centrally located male end perpendicularlysecured thereto, illustrated in FIG. 3. When coupled, the first, secondand third support members will form a substantially rectangularconfiguration, as seen in FIG. 3. As shown, the central male ends of theelongated support member will be facing each other.

[0039] Mating the male ends of the first support member 16 a is the useof a t-shape support member 16 d, as seen in FIG. 3. This t-shape memberhas female receiving ends that receive the male ends of the firstsupport members 16 d, as seen in FIG. 3. Male ends extend outwardly fromthe member to form the t-shape. Coupling this t-shape member to theouter elongated member 16 c is extended members 16 e having outerfemale-receiving ends, illustrated in FIG. 3. Coupled, the t-shapemember 16 d and the pair of extended members 16 e form a t-shape. Toform the frame, all the members are aligned as shown in FIG. 3. Oncealigned, each preceding end of each member is coupled with thesubsequent end. This will provide for the preceding end to be coupled tothe subsequent end and provide for the entire frame to be square andflushed. It is noted that additional support members can be utilized forincreasing and/or decreasing the size of the porch and that the numberand type of supports utilized is dependent upon the size and shape ofthe preferred porch.

[0040] To provide for the main frame 14 to be elevated, verticallyadjustable legs 18 are provided, as shown in FIGS. 1 and 4. The legscomprise an upper end 20 a and a lower end 20 b. The upper end 20 aincludes a brace member 22, illustrated in detail in FIG. 4. Extendingthrough the brace member 22 are pre-drilled apertures. These aperturesare adapted to receive conventional securing elements. Located on thelower end 20 b is an enlarged area that aids in supporting the mainframe 14 when the legs are secured thereto. Each leg includes aconventional telescopic adjusting mechanism to allow the leg toindependently adjust vertically. Once the desired height is reached, theleg is locked into place via conventional locking mechanisms 24.

[0041] The legs 18 are secured to the lower surface of the main frame 14via conventional securing elements, such as self-tapping screws. Asseen, the brace 22 is located at each corner of the frame and on eachside joint. The apertures of the brace 22 will receive the conventionalsecuring elements for rending attachment thereto. For added stability,the center joints C can be secured via conventional securing elements,such as self-tapping screws.

[0042] Once the framed as been assembled, as seen in FIG. 1, the deckingmaterial 64 can be secured thereto. The decking material can be of anyconventional form and in the preferred embodiment is conventionaldecking lumber. When installing the lumber, one end of the wood will beflushed with the end of the frame while the second end of the wood willoverhang slightly with respect to the second end of the frame. Once thelumber has been placed on, it is secured to the frame 14 viaconventional securing elements, such as self-tapping screws.

[0043] When the decking has been completed, the rail assembly can bemounted thereto. This rail assembly 26 is illustrated in FIGS. 1 and 5a.As illustrated, the rail assembly comprises vertical support members 28a, 28 b, and 28 c. These vertical support members will maintain thelower horizontal rail member 42 and the upper horizontal handrail member46. The lower horizontal rail members and the upper horizontal handrailmembers will accept the balusters.

[0044] Each vertical support member 28 a, 28 b and 28 c includes anupper portion having at least one male end 32, which is illustrated asswedged, and a lower portion including a brace 34. The brace includespre-drilled apertures for receiving conventional attaching devices, suchas self-tapping screws. The brace can include the same shape andconfiguration, or optionally can include a configuration for optimizingits support. As seen corner braces will be triangular in shape andnon-corner braces will be substantially square in configuration.Extending horizontally through the lower area of each vertical supportmember is a channel 40. The channel 40 is located in proximity to thebrace and is configured to receive a conventional attaching device.

[0045] Exterior corners will receive the exterior corner support members28 a, interior corners will receive the interior corner support members28 b, and additional support members 28 c will be located as necessary.Exterior corners are the corners that are not located adjacent to thehome. Accordingly, each exterior corner pieces 28 a will include a pairof vertical shafts 36, which are coupled via reinforcement members 38.This coupling provides added stability. Each upper end of each verticalshaft will include the male end, which will be swedged to provide areduced circumference for insertion into a female open end. The lowerend of each shaft will be secured to a singular brace.

[0046] Interior corners are the support members that are locatedadjacent to the home. The interior corner support members 28 b include asingular vertical shape. Each upper end of each shaft will include themale end. The lower end will be secured to the brace.

[0047] Additional support members 28 c will be utilized. These supportmembers will be located at a particular distance from the exteriorcorner members and/or interior corner support members. This particulardistance is pre-determined by the manufacture. This distance iscalculated upon size of the deck, appropriate support properties forlower railings 42, upper railings 46 and balusters 52. The additionalsupporting members 28 c include a singular vertical shape. Each upperend of each shaft will include the male end. The lower end will besecured to the brace. The difference between the additional supportmember 28 c and the interior support members 28 b resides in the shapeof the brace.

[0048] Accordingly, the corner support members will be secured to eachcorner of the decking. For securing to the decking, the user places thebrace on the deck and secures it thereto by conventional attachingdevices, such as self-tapping screws. The screws are placed into theexisting holes located through the brace. Once the corner supportmembers are secured aligned with the corner support member and areattached to the decking as defined above.

[0049] Lower railings 42 are used to receive the lower ends of thebalusters 52. The lower railings 42 are elongated poles having aplurality of receiving apertures 44 located along one side thereon. Theouter ends of the lower railing include openings for receiving aconventional attaching device. Thus the lower are situated between apair of support members, with the receiving apertures 44 facingupwardly, opposite from the deck. The openings are aligned to thechannels of the support member. Once aligned, a conventional attachingdevice is inserted in the channel of the support member and to theopening of the outer end of the lower railing. This will provide for thepiece to be secured thereto. The process is continued with each end ofeach railing member to provide for the lower railings 42 to be securedthereto. It is noted that a gap will be located between a pair ofrailing. The gap will provide for the pair of railing to be free fromrailings so as to provide and entrance to the decking assembly 12. Thestair assembly will be attached to this gap area.

[0050] After the lower railing is attached, the upper railing or toprail 46 is coupled to each pair of support members and above each lowerrailing 42. The top rail includes a C-shape configuration wherein eachouter flange member includes a female receiving portion 48. Extendingalong the interior of the center member is a plurality of apertures 50that are alignable with the apertures of the lower railing. Thus toattached to the support members, the female ends of the upper railings46 receive the male ends of the support member. This provides for theupper railing 46 to be secured to the supports 28 a, 28 b and/or 28 cand also provides for the plurality of apertures 50 of the upper railing46 to be facing the plurality of apertures 44 from the lower railing 42.

[0051] The balusters 52 are inserted into each pair of alignable holeslocated on the lower railing 42 and upper railing 46. The balusters canhave any shape, design or configuration. It is noted that the supportmembers can be attached to the deck after the lower rail assembly hasbeen secured to the upper rail assembly and the balusters have beeninserted into the appropriate apertures.

[0052] Secured to the gap or opening of the rail assembly is the stepassembly 54. This step assembly is shown in FIGS. 1, 2, and 10 a and 10b. As seen, the step assembly will include at least two step framemembers 56. The step frame members include a step configuration whereinthe top includes a receiving opening 58 for receiving a conventionalattaching element, such as a carriage bolt. The lower end includestelescoping legs 60 similar in design as to the legs 18 used to supportand elevate the main frame 14. Accordingly, each leg 60 includes aconventional telescopic adjusting mechanism to allow the leg toindependently adjust vertically. Once the desired height is reached, theleg is locked into place via conventional locking mechanisms. Located onthe lower end of each leg of the step frame is an enlarged area thataids in supporting the step assembly.

[0053] Each step frame member 56 includes a lower tubular member 66 forreceiving the telescoping legs 60. As well as receiving the telescopinglegs, each lower tubular member of the step frame members may receive anadditional step frame member 56. Thereby, additional steps may be addedto the step assembly 54. The additional step frame member includes anupper tubular member 68 opposite a lower tubular member 66, connected bythe center step support member 70. The upper tubular member 68 isreceived by the tubular opening of the above situate lower tubularmember 66 of a second step frame member. Each of the joined step framemembers are attached by conventional means similar to the means used insecuring the telescoping leg member for interchangeability. A desiredmeans for attached the step frame members would include providingswedged ends for interlocking with female receiving ends. Thetelescoping legs 60 on the front of the step assembly 54 where the stepassembly attaches to the modular structure are designed to telescope asufficient distance to promote the addition of steps via the addition ofstep frame members. Thereby, the step assembly provides a simple andversatile means for accommodating modular structures with varyingentryway heights.

[0054] The step frame members 56 are secured to the main frame 14 viaconventional attaching elements. Once attached, the legs are adjustedand step decking is secured to the upper surface of the frame members56. The decking will be secured via conventional devices such asself-taping screws or the like.

[0055] Various features can be added for enhancing the final product.For example, a handrail assembly 62 can be provided and a canopy can belocated above the decking for protection against all weather conditions.The addition of a handrail assembly 62 may be designed in conjunctionwith the step assembly 54 to accommodate the addition of step framemembers 56 for added steps. A handrail assembly may be provided on eachside of the step assembly to provide easy and secure climbing of thesteps.

[0056] As shown in FIG. 11, the handrail system may include a firsttubular upper handrail member 72 having an open end for receiving theswedged (reduced diameter) end 76 of an additional handrail segment 74.An additional support leg 78, baluster segment 80, and plastic end plug82 may be provided to complete the handrail extension in refinedfashion. The additional support leg may be attached to the firsthandrail member 72 or to the an additional handrail segment 74 as neededto provide a lower support for the handrail assembly on the stepassembly.

[0057] While the present invention has been particularly shown anddescribed with reference to an embodiment thereof, it will be understoodby those skilled in the art that various changes in form and detail maybe made without departing from the spirit and scope of the presentinvention.

I claim:
 1. A modular porch apparatus comprising: a main deck frameconstructed of a plurality of support members having connecting endmembers, including swedged end members having reduced circumference andfemale receiving end members arranged to receive the swedged end membersfor interconnecting said support members; vertically adjustable legsattached to the main deck frame and extending downwardly; a deckingmaterial secured on the main deck frame providing a flat horizontal decksurface; a railing assembly attached to said deck surface; said railingassembly including at least two vertically oriented elongate lowermembers; said lower members each including a first connecting end; saidlower members supporting a lower horizontal rail having a plurality ofapertures along its span; a plurality of balusters inserted into theapertures of said lower horizontal rail; an upper horizontal handrailincluding second connecting ends; either said first connecting ends orsecond connecting ends being swedged and of reduced circumference; saidvertically oriented lower members connected to said upper horizontalhandrail by insertion of the first connecting end of the lower membersinto the second connecting ends of the upper handrail; and, said upperhorizontal handrail further including a plurality of apertures along itsspan that receive said balusters and lock said balusters into place withthe connection of the upper horizontal handrail to the lower members. 2.A modular porch apparatus comprising: a pair of elongate peripheralC-shape support members, each C-shape support member having an axiallyaligned receiving end and two perpendicular disposed receiving ends; apair of elongate peripheral L-shape support members, each L-shapesupport member having a perpendicular disposed receiving end and anaxially aligned receiving end; a pair of elongate peripheral thirdsupport members, each third support member having two axially alignedreceiving ends thereon and a perpendicularly disposed receiving endcentrally located on each of the third pair of support members; anelongate interior T-shape support member having axially alignedreceiving ends and perpendicular receiving ends centrally located on theT-shape member and extending outwardly to form a T-shape; a pair ofelongate interior fifth support members that are substantially straight,each fifth support member having axially aligned receiving ends; saidC-shape support members, L-shape support members, third support members,interior T-shape support member, and interior fifth support membersconnected to form a rectangular main deck frame; vertically adjustablelegs attached to the main deck frame and extending downwardly; and adecking material attached to the main deck frame to form a deck surface.3. A modular porch apparatus as in claim 2 including: a step assemblyattached to said main deck frame; said step assembly having at least twoconnected step frame members; each step frame member including avertically disposed top member, a horizontally disposed center stepsupport member connected to the top member, and a vertically disposedlower member connected to the center step support member; saidvertically disposed lower member having a tubular section for receivingthe top member of an additional step frame member or a telescoping legmember; and a step decking material attached to the center step supportmember of each step frame member.
 4. A modular porch apparatus as inclaim 3 including an adjustable handrail assembly attached to said stepassembly said handrail assembly including: a first handrail member; afirst handrail segment; said first handrail member having an open endfor receiving said handrail segment, and said handrail segment having aswedged end of reduced circumference for insertion into said open endfor connection of the first handrail segment to the first handrailmember, and said handrail segment having an open end for receiving anadditional handrail segment; and a support leg attached to said firsthandrail member, first handrail segment, or additional handrail segment.5. A modular step assembly comprising: at least two modularly connectedstep frame members; each step frame member including a verticallydisposed top member, a horizontally disposed center step support memberconnected to the top member, and a vertically disposed lower memberconnected to the center step support member; said vertically disposedlower member having a tubular section for receiving a top member of anadditional step frame member or a telescoping leg member; and a stepdecking material attached to the center step support member of each stepframe member.
 6. A modular handrail assembly comprising: a firsthandrail member; a first handrail segment; said first handrail memberhaving an open end for receiving said handrail segment, and saidhandrail segment having a swedged end of reduced circumference forinsertion into said open end for connection of the first handrailsegment to the first handrail member, and said handrail segment havingan open end for receiving an additional handrail segment; and a supportleg attached to said first handrail member, first handrail segment, oradditional handrail segment.
 7. A combination modular step assembly andmodular handrail assembly comprising: at least two modularly connectedstep frame members; each step frame member including a verticallydisposed top member, a horizontally disposed center step support memberconnected to the top member, and a vertically disposed lower memberconnected to the center step support member; said vertically disposedlower member having a tubular section for receiving a top member of anadditional step frame member or a telescoping leg member; a step deckingmaterial attached to the center step support member of each step framemember; a first handrail member having a first support leg forsupporting and attaching the first handrail member to the step assembly;a first handrail segment; said first handrail member having an open endfor receiving said handrail segment, and said handrail segment having aswedged end of reduced circumference for insertion into said open endfor connection of the first handrail segment to the first handrailmember, and said handrail segment having an open end for receiving anadditional handrail segment; and a support leg attached to said firsthandrail member, first handrail segment, or additional handrail segmentand supporting said handrail assembly on the step assembly.